Surgical forceps and method of manufacturing thereof

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation application of and claims the priority to U.S. patent application Ser. No. 14/284,618, filed on May 22, 2014, which is a continuation of U.S. patent application Ser. No. 13/179,919, filed on Jul. 11, 2011, now U.S. Pat. No. 8,745,840, the entire contents of each of these applications is incorporated herein by reference.

BACKGROUND

Technical Field

The present disclosure relates to surgical instruments and, more particularly, to surgical forceps and methods of manufacturing surgical forceps.

Background of Related Art

A forceps is a plier-like instrument which relies on mechanical action between its jaws to grasp, clamp and constrict vessels or tissue. Electrosurgical forceps utilize both mechanical clamping action and electrical energy to affect hemostasis by heating tissue and blood vessels to coagulate and/or cauterize tissue. Certain surgical procedures require more than simply cauterizing tissue and rely on the unique combination of clamping pressure, precise electrosurgical energy control and gap distance (i.e., distance between opposing jaw members when closed about tissue) to “seal” tissue, vessels and certain vascular bundles. Typically, once a vessel is sealed, the surgeon has to accurately sever the vessel along the newly formed tissue seal. Accordingly, many vessel sealing instruments have been designed which incorporate a knife or blade member that effectively severs the tissue after forming a tissue seal.

SUMMARY

In accordance with one embodiment of the present disclosure, a method of manufacturing a forceps is provided. The method includes providing first and second jaw members and depositing an electrically-conductive tissue sealing plate atop each jaw member via vapor deposition. The jaw members are then coupled to one another to permit movement of one (or both) of the jaw members between a spaced-apart position and an approximated position for grasping tissue between the tissue sealing plates thereof.

In one embodiment, the vapor deposited includes physical vapor deposition. Alternatively, the vapor deposition may include chemical vapor deposition.

In another embodiment, the tissue sealing plates are deposited atop insulators of the jaw members. The insulators may be formed via injection molding and/or may be engaged within jaw frames of the respective jaw members, e.g., via snap-fitting.

In yet another embodiment, each of the jaw frames includes a proximal flange extending proximally therefrom. The proximal flanges may be pivotably coupled to one another to permit movement of the jaw members relative to one another between the spaced-apart position and the approximated position.

In still another embodiment, the method further includes molding a wire within one (or both) of the jaw members such that the wire is disposed in electrically communication with the tissue sealing plate thereof for supplying electrosurgical energy to the tissue sealing plate.

A method of manufacturing a jaw member of a forceps is provided in accordance with another embodiment of the present disclosure. The method includes providing an insulator and a jaw frame, forming an electrically-conductive tissue sealing plate atop the insulator via vapor deposition, and engaging the insulator to the jaw frame.

In one embodiment, the insulator is formed via injection molding. The vapor deposition may include physical vapor deposition, chemical vapor deposition, or other suitable deposition process.

In yet another embodiment, a wire is molded to the insulator prior to forming the tissue sealing plate atop the insulator. When the tissue sealing plate is formed atop the insulator, the tissue sealing plate is disposed in electrical communication with the wire.

Another method of manufacturing a jaw member of a forceps is provided in accordance with the present disclosure. In this embodiment, the method includes injection molding an insulator and vapor depositing an electrically-conductive tissue sealing plate atop the insulator.

The method may further include engaging the insulator to a jaw frame and/or electrically coupling the tissue sealing plate to a source of electrosurgical energy, e.g., via a wire molded to the insulator and disposed in electrical communication with the tissue sealing plate.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure are described herein with reference to the drawings wherein:

<figref idref="DRAWINGS">FIG. 1</figref> is a front, perspective view of an endoscopic surgical forceps configured for use in accordance with the present disclosure;

<figref idref="DRAWINGS">FIG. 2</figref> is a front, perspective view of an open surgical forceps configured for use in accordance with the present disclosure;

<figref idref="DRAWINGS">FIG. 3</figref> is an enlarged, front, perspective view of an end effector assembly configured for use with the forceps of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 4</figref> is an enlarged, front, perspective view of the end effector assembly of <figref idref="DRAWINGS">FIG. 3</figref> wherein one of the jaw members of the end effector assembly is shown with parts separated;

<figref idref="DRAWINGS">FIG. 5A</figref> is a longitudinal, cross-sectional view of one embodiment of an insulator configured for use with one of the jaw members of the end effector assembly of <figref idref="DRAWINGS">FIG. 3</figref>;

<figref idref="DRAWINGS">FIG. 5B</figref> is a longitudinal, cross-sectional view of the insulator of <figref idref="DRAWINGS">FIG. 5A</figref> including a sealing plate disposed thereon and in position for assembly with a jaw frame of the jaw member;

<figref idref="DRAWINGS">FIG. 5C</figref> is a longitudinal, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 5B</figref> in an assembled condition;

<figref idref="DRAWINGS">FIG. 6A</figref> is a transverse, cross-sectional view of another embodiment of an insulator configured for use with one of the jaw members of the end effector assembly of <figref idref="DRAWINGS">FIG. 3</figref>;

<figref idref="DRAWINGS">FIG. 6B</figref> is a transverse, cross-sectional view of the insulator of <figref idref="DRAWINGS">FIG. 6A</figref> including a sealing plate disposed thereon and in position for assembly with a jaw frame of the jaw member;

<figref idref="DRAWINGS">FIG. 6C</figref> is a transverse, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 6B</figref> in an assembled condition;

<figref idref="DRAWINGS">FIG. 7A</figref> is a longitudinal, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 5C</figref> including an electrical connection in accordance with one embodiment of the present disclosure;

<figref idref="DRAWINGS">FIG. 7B</figref> is a transverse, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 7A</figref>;

<figref idref="DRAWINGS">FIG. 8A</figref> is a longitudinal, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 5C</figref> including yet another embodiment of an electrical connection provided in accordance with the present disclosure;

<figref idref="DRAWINGS">FIG. 8B</figref> is a transverse, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 8A</figref>; and

<figref idref="DRAWINGS">FIG. 9</figref> is a longitudinal, cross-sectional view of the jaw member of <figref idref="DRAWINGS">FIG. 5C</figref> including another embodiment of an electrical connection provided in accordance with the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. As used herein, the term “distal” refers to the portion that is being described which is further from a user, while the term “proximal” refers to the portion that is being described which is closer to a user.

Referring now to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, <figref idref="DRAWINGS">FIG. 1</figref> depicts a forceps <b>10</b> for use in connection with endoscopic surgical procedures and <figref idref="DRAWINGS">FIG. 2</figref> depicts an open forceps <b>10</b>′ contemplated for use in connection with traditional open surgical procedures. For the purposes herein, either an endoscopic instrument, e.g., forceps <b>10</b>, or an open instrument, e.g., forceps <b>10</b>′, may be utilized in accordance with the present disclosure. Obviously, different electrical and mechanical connections and considerations apply to each particular type of instrument; however, the novel aspects with respect to the end effector assembly and its operating characteristics remain generally consistent with respect to both the open and endoscopic configurations.

Turning now to <figref idref="DRAWINGS">FIG. 1</figref>, an endoscopic forceps <b>10</b> is provided defining a longitudinal axis “X-X” and including a housing <b>20</b>, a handle assembly <b>30</b>, a rotating assembly <b>70</b>, a trigger assembly <b>80</b> and an end effector assembly <b>100</b>. Forceps <b>10</b> further includes a shaft <b>12</b> having a distal end <b>14</b> configured to mechanically engage end effector assembly <b>100</b> and a proximal end <b>16</b> that mechanically engages housing <b>20</b>. Forceps <b>10</b> also includes electrosurgical cable <b>610</b> that connects forceps <b>10</b> to a generator (not shown) or other suitable power source, although forceps <b>10</b> may alternatively be configured as a battery powered instrument. Cable <b>610</b> includes a wire (or wires) (not shown) extending therethrough that has sufficient length to extend through shaft <b>12</b> in order to provide electrical energy to at least one of the sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively, of end effector assembly <b>100</b>, e.g., upon activation of activation switch <b>90</b>.

With continued reference to <figref idref="DRAWINGS">FIG. 1</figref>, handle assembly <b>30</b> includes fixed handle <b>50</b> and a moveable handle <b>40</b>. Fixed handle <b>50</b> is integrally associated with housing <b>20</b> and handle <b>40</b> is moveable relative to fixed handle <b>50</b>. Rotating assembly <b>70</b> is rotatable in either direction about longitudinal axis “X-X” to rotate end effector <b>100</b> about longitudinal axis “X-X.” Housing <b>20</b> houses the internal working components of forceps <b>10</b>.

End effector assembly <b>100</b> is shown attached at a distal end <b>14</b> of shaft <b>12</b> and includes a pair of opposing jaw members <b>110</b> and <b>120</b>. Each of the jaw members <b>110</b> and <b>120</b> includes an opposed electrically conductive tissue-sealing plate <b>116</b>, <b>126</b>, respectively. End effector assembly <b>100</b> is designed as a unilateral assembly, i.e., where jaw member <b>120</b> is fixed relative to shaft <b>12</b> and jaw member <b>110</b> is moveable about pivot <b>103</b> relative to shaft <b>12</b> and fixed jaw member <b>120</b>. However, end effector assembly <b>100</b> may alternatively be configured as a bilateral assembly, i.e., where both jaw member <b>110</b> and jaw member <b>120</b> are moveable about a pivot <b>103</b> relative to one another and to shaft <b>12</b>. In some embodiments, a knife assembly (not shown) is disposed within shaft <b>12</b> and a knife channel <b>125</b> (<figref idref="DRAWINGS">FIG. 3</figref>) is defined within one or both jaw members <b>110</b>, <b>120</b> to permit reciprocation of a knife blade (not shown) therethrough, e.g., via activation of a trigger <b>82</b> of trigger assembly <b>80</b>. The particular features of end effector assembly <b>100</b> will be described in greater detail hereinbelow.

Continuing with reference to <figref idref="DRAWINGS">FIG. 1</figref>, moveable handle <b>40</b> of handle assembly <b>30</b> is ultimately connected to a drive assembly (not shown) that, together, mechanically cooperate to impart movement of jaw members <b>110</b> and <b>120</b> between a spaced-apart position and an approximated position to grasp tissue between sealing plates <b>116</b> and <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively. As shown in <figref idref="DRAWINGS">FIG. 1</figref>, moveable handle <b>40</b> is initially spaced-apart from fixed handle <b>50</b> and, correspondingly, jaw members <b>110</b>, <b>120</b> are in the spaced-apart position. Moveable handle <b>40</b> is actuatable from this initial position to a depressed position corresponding to the approximated position of jaw members <b>110</b>, <b>120</b>.

Referring now to <figref idref="DRAWINGS">FIG. 2</figref>, an open forceps <b>10</b>′ is shown including two elongated shafts <b>12</b><i>a </i>and <b>12</b><i>b</i>, each having a proximal end <b>16</b><i>a </i>and <b>16</b><i>b</i>, and a distal end <b>14</b><i>a </i>and <b>14</b><i>b, </i>respectively. Similar to forceps <b>10</b> (<figref idref="DRAWINGS">FIG. 1</figref>), forceps <b>10</b>′ is configured for use with end effector assembly <b>100</b>. More specifically, end effector assembly <b>100</b> is attached to distal ends <b>14</b><i>a </i>and <b>14</b><i>b </i>of shafts <b>12</b><i>a </i>and <b>12</b><i>b</i>, respectively. As mentioned above, end effector assembly <b>100</b> includes a pair of opposing jaw members <b>110</b> and <b>120</b> that is pivotably connected about a pivot <b>103</b>. Each shaft <b>12</b><i>a </i>and <b>12</b><i>b </i>includes a handle <b>17</b><i>a </i>and <b>17</b><i>b </i>disposed at the proximal end <b>16</b><i>a </i>and <b>16</b><i>b </i>thereof. Each handle <b>17</b><i>a </i>and <b>17</b><i>b </i>defines a finger hole <b>18</b><i>a </i>and <b>18</b><i>b </i>therethrough for receiving a finger of the user. As can be appreciated, finger holes <b>18</b><i>a </i>and <b>18</b><i>b </i>facilitate movement of the shafts <b>12</b><i>a </i>and <b>12</b><i>b </i>relative to one another which, in turn, pivots jaw members <b>110</b> and <b>120</b> from an open position, wherein the jaw members <b>110</b> and <b>120</b> are disposed in spaced-apart relation relative to one another, to a closed position, wherein the jaw members <b>110</b> and <b>120</b> cooperate to grasp tissue therebetween.

A ratchet <b>30</b>′ may be included for selectively locking the jaw members <b>110</b> and <b>120</b> relative to one another at various positions during pivoting. Ratchet <b>30</b>′ may include graduations or other visual markings that enable the user to easily and quickly ascertain and control the amount of closure force desired between the jaw members <b>110</b> and <b>120</b>.

With continued reference to <figref idref="DRAWINGS">FIG. 2</figref>, one of the shafts, e.g., shaft <b>12</b><i>b</i>, includes a proximal shaft connector <b>19</b> that is designed to connect the forceps <b>10</b>′ to a source of electrosurgical energy such as an electrosurgical generator (not shown). Proximal shaft connector <b>19</b> secures an electrosurgical cable <b>610</b>′ to forceps <b>10</b>′ such that the user may selectively apply electrosurgical energy to the electrically conductive sealing plates <b>116</b> and <b>126</b> of jaw members <b>110</b> and <b>120</b>, respectively, as needed.

Forceps <b>10</b>′ may further include a knife assembly (not shown) disposed within either of shafts <b>12</b><i>a</i>, <b>12</b><i>b </i>and a knife channel <b>125</b> (<figref idref="DRAWINGS">FIG. 3</figref>) defined within one or both of jaw members <b>110</b>, <b>120</b>, respectively, to permit reciprocation of a knife blade (not shown) therethrough.

Turning now to <figref idref="DRAWINGS">FIGS. 3-4</figref>, end effector assembly <b>100</b>, including jaw members <b>110</b> and <b>120</b> is configured for use with either forceps <b>10</b> or forceps <b>10</b>′, discussed above, or any other suitable surgical instrument capable of pivoting jaw members <b>110</b>, <b>120</b> relative to one another between a spaced-apart position and an approximated position for grasping tissue therebetween. However, for purposes of simplicity and consistency, end effector assembly <b>100</b> will be described hereinbelow with reference to forceps <b>10</b> only. Further, jaw members <b>110</b>, <b>120</b> are substantially similar to one another and, thus, the features described herein with respect to jaw member <b>110</b> or jaw member <b>120</b> apply similarly to the other jaw member <b>110</b>, <b>120</b>.

With continued reference to <figref idref="DRAWINGS">FIGS. 3-4</figref>, jaw members <b>110</b>, <b>120</b> each include a jaw frame <b>112</b>, <b>122</b>, an insulator <b>114</b>, <b>124</b> engaged to the respective jaw frame <b>112</b>, <b>122</b> thereof, an electrically-conductive tissue sealing plate <b>116</b>, <b>126</b> disposed atop insulator <b>114</b>, <b>124</b>, respectively, and an outer jaw housing <b>118</b>, <b>128</b> configured to house the components of jaw members <b>110</b>, <b>120</b>, respectively, therein. Jaw frames <b>112</b>, <b>122</b> each include a proximal flange <b>113</b>, <b>123</b> extending proximally therefrom. Jaw frames <b>112</b>, <b>122</b> and proximal flanges <b>113</b>, <b>123</b> of each jaw member <b>110</b>, <b>120</b>, respectively, are formed as a single, monolithic component. Proximal flanges <b>113</b>, <b>123</b> are pivotably coupled to one another via pivot pin <b>103</b> to permit pivotable movement of jaw members <b>110</b>, <b>120</b> relative to one another between the spaced-apart position and the approximated position for grasping tissue therebetween. Jaw frames <b>112</b>, <b>122</b> are further configured, as mentioned above, to engage insulators <b>114</b>, <b>124</b>, respectively, thereon. Insulators <b>114</b>, <b>124</b>, in turn, are configured to receive electrically-conductive tissue sealing plates <b>116</b>, <b>126</b>, respectively, thereon such that tissue sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively, oppose one another. Accordingly, when jaw members <b>110</b>, <b>120</b> are moved to the approximated position with tissue disposed therebetween, tissue is grasped between the opposed tissue sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively. Further, one or both of tissue sealing plates <b>116</b>, <b>126</b> is adapted to connect to a source of electrosurgical energy (not shown) for conducting energy therebetween and through tissue to seal tissue grasped between jaw members <b>110</b>, <b>120</b>. Various configurations of and methods for manufacturing end effector assembly <b>100</b>, or the components thereof, are described in detail hereinbelow.

Referring now to <figref idref="DRAWINGS">FIGS. 5A-5C</figref>, the configuration and manufacture of jaw member <b>120</b> in accordance with an embodiment of the present disclosure is described. The configuration and manufacture of jaw member <b>110</b> is similar to that of jaw member <b>120</b> and, thus, is not described to avoid unnecessary repetition. As mentioned above, jaw member <b>120</b> includes a jaw frame <b>122</b> including a proximal flange <b>123</b> extending proximally therefrom, an insulator <b>124</b>, and a tissue sealing plate <b>126</b>. Jaw frame <b>122</b>, including proximal flange <b>123</b> is formed from stainless steel, or other suitable material that is sufficiently strong and rigid to permit accurate and consistent movement of jaw members <b>110</b>, <b>120</b> between the spaced-apart and approximated positions for grasping tissue therebetween, to ensure that an accurate and consistent closure pressure is imparted to tissue grasped between jaw members, and to retain the other components of jaw member <b>120</b> in position thereon. Insulator <b>124</b> may formed from an electrically-insulative material and is configured to electrically insulate tissue sealing plate <b>126</b> from the remaining components of jaw member <b>120</b>, e.g., jaw frame <b>122</b>. Insulator <b>124</b> may be formed via injection-molding, or any other suitable manufacturing process. Tissue sealing plate <b>126</b> may be formed from any suitable electrically-conductive material and is disposed on insulator <b>124</b>. Tissue sealing plate <b>126</b> is configured, in conjunction with tissue sealing plate <b>116</b> of jaw member <b>110</b> (<figref idref="DRAWINGS">FIGS. 3-4</figref>), to grasp and seal tissue disposed between jaw members <b>110</b>, <b>120</b> (<figref idref="DRAWINGS">FIGS. 3-4</figref>).

Continuing with reference to <figref idref="DRAWINGS">FIGS. 5A-5C</figref>, and initially to <figref idref="DRAWINGS">FIG. 5A</figref>, during manufacturing, insulator <b>124</b> and tissue sealing plate <b>126</b> are formed as a single component, thus obviating the need to mechanically, or otherwise engage tissue sealing plate <b>126</b> to insulator <b>124</b> and/or other components of jaw member <b>120</b>. Such a configuration also reduces part count, obviates the need to form more complex features into insulator <b>124</b> and tissue sealing plate <b>126</b> for engaging these components to one another, and/or obviates the need for more complex assembly processes. In particular, tissue sealing plate <b>126</b> may be formed atop insulator <b>124</b> during manufacturing via vapor deposition (vacuum deposition), e.g., physical vapor deposition or chemical vapor deposition. Physical vapor deposition involves heating a material, e.g., the material to form tissue sealing plate <b>126</b>, to a vaporous state and exposing the vaporous material to a substrate, e.g., insulator <b>124</b>, such that the vaporous material is deposited, or condensates on the surface of the substrate, thereby forming a film, or plate of material disposed on the substrate. Such a process may be used to deposit sufficient material onto insulator <b>124</b> so as to form tissue sealing plate <b>126</b> thereon.

Chemical vapor deposition involves exposing a substrate, e.g., insulator <b>124</b>, to one or more precursors that react with one another and/or decompose to form a thin film, or plate of deposit on the surface of the substrate. As such, the precursors may be selected so as to produce the material to form tissue sealing plate <b>126</b>, such that chemical vapor deposition may be used to form tissue sealing plate <b>126</b> on insulator <b>124</b>. Other similar, suitable processes for depositing, or forming tissue sealing plate <b>126</b> on insulator <b>124</b> include thermal spraying, metallizing (vacuum metalizing), and other vacuum deposition processes.

With continued reference to <figref idref="DRAWINGS">FIGS. 5A-5C</figref>, and to <figref idref="DRAWINGS">FIG. 5B</figref> in particular, with tissue sealing plate <b>126</b> formed on insulator <b>124</b> as a single component, e.g., via vapor deposition, insulator <b>124</b> may be engaged to jaw frame <b>122</b> of jaw member <b>120</b>. Insulator <b>124</b> includes a pair of snap-fit members <b>132</b> configured to snap-fittingly engage corresponding apertures <b>134</b> defined through jaw frame <b>122</b> to engage insulator <b>124</b> and, thus, tissue sealing plate <b>126</b>, atop jaw frame <b>122</b>. More specifically, in order to engage insulator <b>124</b> to jaw frame <b>122</b>, snap-fit members <b>132</b> of insulator <b>124</b> are urged into apertures <b>134</b> of jaw frame <b>122</b>, thereby resiliently compressing snap-fit members <b>132</b> to accommodate snap-fit members <b>132</b> within apertures <b>134</b>. Upon further translation of snap-fit members <b>132</b> through apertures <b>134</b>, snap-fit members <b>132</b> eventually extend from apertures <b>134</b> on the opposite side of jaw frame <b>122</b>, thus allowing snap-fit members <b>132</b> to resiliently bias, or snap, back to the initial, uncompressed condition. With snap-fit members <b>132</b> disposed through apertures <b>134</b> in the uncompressed condition, snap-fit members <b>132</b> are inhibited from being withdrawn, or backed out of apertures <b>134</b>, thereby securely engaging insulator <b>124</b> atop jaw frame <b>122</b>. Although two snap-fit members <b>132</b> and apertures <b>134</b> are shown, greater or fewer than two snap-fit members <b>132</b> and apertures <b>134</b> may be provided. Further, any other suitable mechanism for engaging insulator <b>124</b> and jaw frame <b>122</b> may alternatively be provided. Injection-molding insulator <b>124</b> is particularly advantageous in that injection-molding provides a relatively simple and inexpensive process for forming insulator <b>124</b> including snap-fit members <b>132</b> (or any other suitable engagement structures, e.g., tabs <b>232</b> of insulator <b>224</b> (<figref idref="DRAWINGS">FIGS. 6A-6C</figref>)).

Turning now to <figref idref="DRAWINGS">FIGS. 6A-6C</figref>, the configuration and manufacture of jaw member <b>220</b> in accordance with another embodiment of the present disclosure is described. Insulator <b>224</b> is formed from an electrically-insulative material, e.g., via injection molding, and includes a pair of opposed, outwardly-extending tabs <b>232</b> extending therefrom. Insulator <b>224</b> further includes a knife channel <b>225</b> defined therein and extending longitudinally therethrough. Knife channel <b>225</b> is configured to permit reciprocation of a knife blade (not shown) therethrough for cutting tissue grasped between jaw member <b>220</b> and the opposed jaw member (not shown) thereof. Once insulator <b>224</b> has been formed, e.g., via injection-molding, tissue sealing plate <b>226</b> may be formed atop insulator <b>224</b> via vapor deposition, e.g., physical vapor deposition or chemical vapor deposition, or other suitable deposition process.

Continuing with reference to <figref idref="DRAWINGS">FIGS. 6A-6C</figref>, and to <figref idref="DRAWINGS">FIG. 6B</figref> in particular, with tissue sealing plate <b>226</b> formed atop insulator <b>224</b>, insulator <b>224</b> and tissue sealing plate <b>226</b> may be engaged within jaw frame <b>222</b>. As shown in <figref idref="DRAWINGS">FIG. 6B</figref>, jaw frame <b>222</b> defines a cavity <b>236</b> that is shaped complementary to insulator <b>224</b> and is configured to receive insulator <b>224</b> at least partially therein. Jaw frame <b>222</b> further includes a pair of notches <b>238</b> defined within the inner surface thereof formed by cavity <b>236</b>. Notches <b>238</b> are configured to receive tabs <b>232</b> of insulator <b>224</b> therein to engage jaw frame <b>222</b> and insulator <b>224</b> to one another, as will be described below.

Referring still to <figref idref="DRAWINGS">FIGS. 6A-6C</figref> and, more particularly, to <figref idref="DRAWINGS">FIG. 6C</figref>, in order to engage insulator <b>224</b> and tissue sealing plate <b>226</b> to jaw frame <b>222</b>, insulator <b>224</b> is urged into cavity <b>236</b> defined within jaw frame <b>222</b>. More specifically, insulator <b>224</b> may defined a diameter substantially similar, or slightly smaller than that of jaw frame <b>222</b> to establish a press-fit, or friction-fit engagement therebetween. As such, tabs <b>232</b> extending from insulator <b>224</b> are resiliently flexed, or compressed to permit advancement of insulator <b>224</b> into jaw frame <b>222</b>. Upon further advancement of insulator <b>224</b> into cavity <b>236</b> of jaw frame <b>222</b>, tabs <b>232</b> of insulator <b>224</b> are positioned adjacent notches <b>238</b> defined within jaw frame <b>222</b>. Once tabs <b>232</b> are moved into position adjacent notches <b>238</b>, tabs <b>232</b> are permitted to resiliently return to their initial position such that tabs <b>232</b> are biased into engagement with notches <b>238</b> to engage insulator <b>224</b> and jaw frame <b>222</b> to one another. Insulator <b>224</b> may include a plurality of tabs <b>232</b> extending therefrom in any configuration and/or tabs <b>232</b> may define elongated configurations extending along the length of insulator <b>224</b>. Notches <b>238</b> are configured complementarily to tabs <b>232</b> and, thus, the number and/or configuration of notches <b>238</b> defined within jaw frame <b>222</b> may depend at least in part on the number and/or configuration of tabs <b>232</b>.

Referring now to <figref idref="DRAWINGS">FIGS. 7A-9</figref>, various electrical connections for electrically coupling tissue sealing plate <b>126</b> of jaw member <b>120</b> to the source of electrosurgical energy (not shown) are described. Although reference is made to jaw member <b>120</b>, it is envisioned that the electrical connections described herein may alternatively be used in conjunction with any of the other jaw members described herein, or any other suitable jaw member, in particular a jaw member including a jaw frame and an insulator engaged to the jaw frame that has a tissue sealing plate formed thereon via vapor deposition.

One electrical connection is shown in <figref idref="DRAWINGS">FIGS. 7A-7B</figref> and includes wire <b>310</b> for electrically coupling tissue sealing plate <b>126</b> of jaw member <b>120</b> to a source of energy (not shown) to energizing tissue sealing plate <b>126</b> (and/or tissue sealing plate <b>116</b> (<figref idref="DRAWINGS">FIGS. 3-4</figref>)) for sealing tissue grasped between tissue sealing plates <b>116</b>, <b>126</b> of respective jaw members <b>110</b>, <b>120</b> (see <figref idref="DRAWINGS">FIGS. 3-4</figref>). More specifically, insulator <b>124</b> may include a groove, or slot <b>140</b> defined therein, e.g., formed therein during injection molding of insulator <b>124</b>, that is configured to receive wire <b>310</b> therein to permit electrical communication between wire <b>310</b> and tissue sealing plate <b>126</b>. In other words, wire <b>310</b> is positioned within slot <b>140</b> of insulator <b>124</b> prior to the vapor deposition of tissue sealing plate <b>126</b> thereon such that, upon deposition of tissue sealing plate <b>126</b> atop insulator <b>124</b>, a portion of tissue sealing plate <b>126</b> is deposited atop the portion of wire <b>310</b> disposed within slot <b>140</b> of insulator <b>124</b>. As such, with wire <b>310</b> contacting tissue sealing plate <b>126</b> after formation of tissue sealing plate <b>126</b> about insulator <b>124</b>, electrosurgical energy may be supplied to tissue sealing plate <b>126</b> via wire <b>310</b> to seal tissue grasped between tissue sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively (see <figref idref="DRAWINGS">FIGS. 3-4</figref>). Further, wire <b>310</b> may be molded, friction-fit, or otherwise engaged within slot <b>140</b> of insulator <b>124</b> to maintain the engagement of wire <b>310</b> within slot <b>140</b> and, thus, to maintain the electrical communication between wire <b>310</b> and tissue sealing plate <b>126</b>.

<figref idref="DRAWINGS">FIGS. 8A-8B</figref> show another embodiment of an electrical connection for electrically coupling tissue sealing plate <b>126</b> to a source of energy (not shown) via wire <b>410</b>. The electrical connection includes a plated aperture <b>420</b> formed within jaw frame <b>122</b> for soldering wire <b>410</b> thereto, thus electrically coupling wire <b>410</b> to jaw frame <b>122</b>. Insulator <b>124</b> may include a lumen extending therethrough that is configured to receive an electrically conductive post <b>430</b> therein for electrically coupling tissue sealing plate <b>126</b> to jaw frame <b>122</b>, although any other suitable configuration for electrically coupling tissue sealing plate <b>126</b> and jaw frame <b>122</b> may alternatively be provided. Thus, with wire <b>410</b> electrically coupled to jaw frame <b>122</b> and with jaw frame <b>122</b> electrically coupled to tissue sealing plate <b>126</b>, electrosurgical energy may be supplied to tissue sealing plate <b>126</b> via wire <b>410</b>, jaw frame <b>122</b>, and post <b>430</b>, to seal tissue grasped between tissue sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively (see <figref idref="DRAWINGS">FIGS. 3-4</figref>).

<figref idref="DRAWINGS">FIG. 9</figref> shows another electrical connection similar to the previous electrical connection except that plated aperture <b>520</b> is formed within proximal flange <b>123</b>. Wire <b>510</b> is soldered to proximal flange <b>123</b> via plated aperture <b>520</b>, electrically coupling wire <b>510</b> to jaw frame <b>122</b>. Jaw frame <b>122</b> is electrically coupled to tissue sealing plate <b>126</b> via any suitable electrical connection such that energy may be supplied via wire <b>510</b> to tissue sealing plate <b>126</b> for sealing tissue grasped between tissue sealing plates <b>116</b>, <b>126</b> of jaw members <b>110</b>, <b>120</b>, respectively (see <figref idref="DRAWINGS">FIGS. 3-4</figref>).

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.